2010 TRANSFER CASE

NV241 GENII ­ Service Information ­ Wrangler

DESCRIPTION
DESCRIPTION

The NV241 GENII transfer case is a part­time transfer case with a low­range gear system. It provides three
operating ranges plus a NEUTRAL position. The low range position provides a gear reduction ratio of 2.72:1
for increased low speed torque capability.

The gear cases and extension are all of aluminum. Drive sprockets and an interconnecting drive chain are used
to transmit engine torque to the front/rear propeller shafts. The mainshaft, input gear and front output shaft are
supported by ball and needle bearings.
IDENTIFICATION

Fig. 1: Transfer Case ­ Rear View

1 ­ TRANSFER CASE
2 ­ IDENTIFICATION TAG

An identification tag (2) is attached to the rear case of every transfer case. The tag provides the transfer case
model number, assembly number, serial number, and low range ratio.

The transfer case serial number also represents the date of build.

OPERA TION
OPERA TION
OPERATING RANGE

Transfer case operating ranges are:

2H (2­wheel drive)
4H (4­wheel drive)
4LO (4­wheel drive low range

The 2H range is for use on any road surface at any time.

4635
The 4H and 4LO ranges are for off road use only. They are not for use on hard surface roads. The only
exception being when the road surface is covered by ice and snow.

The low range reduction gear system is operative in 4LO range only. This range is for extra pulling power in off
road situations. Low range reduction ratio is 2.72:1.
SHIFT MECHANISM

Operating ranges are selected with a floor mounted shift lever. The shift lever is connected to the transfer case
range lever by a shift cable. A straight line shift pattern is used. Range positions are marked on the shifter knob
bezel.

SHIFTING

The transfer case can be shifted between the 2H and 4H operating ranges while the vehicle is in motion. The
vehicle must have the transmission placed in NEUTRAL, or the clutch depressed in the case of a manual
transmission, and be moving less than 2­3 MPH when shifting into and out of the 4L operating range.

DIAGNOSIS AND TESTING

TRANSFER CASE ­ NV241 GENII

Before beginning repair on a suspected transfer case malfunction, check all other driveline components
beforehand.

The actual cause of a problem may be related to such items as: front hubs, axles, propeller shafts, wheels and
tires, transmission, or clutch instead. If all other driveline components are in good condition and operating
properly, refer to the Diagnosis Chart for further information.

DIAGNOSIS CHART
Condition
Transfer Case difficult to shift or 1) Vehicle speed too great to
will not shift into desired range. permit shifting.
Transfer Case noisy in all
operating ranges.
Noisy in, or jumps out of, four
wheel drive low range.
Possible Cause Corr ection
1) Stop vehicle and shift into
desired range. Or, reduce speed to
below 3­4 km/h (2­3 mph) before
attempting the shift.
2) If vehicle was operated for an 2) Stop vehicle and shift the
extended period in 4H on a dry transmission into neutral. Shift the
paved surface, the driveline torque transfer case to 2H and operate
load may be causing a bind. vehicle in 2H on dry paved
surfaces.
3) Transfer case external shift 3) Lubricate, repair, or replace
linkage binding. linkage bushings, or tighten loose
components as necessary.
4) Insufficient or incorrect 4) Drain and refill to edge of fill
lubricant. hole with Mopar® ATF +4,
Automatic Transmission fluid.
5) Internal components binding, 5) Disassemble the transfer case
worn, or damaged. and replace worn or damaged
components as necessary.
1) Insufficient or incorrect 1) Drain and refill to edge of fill
lubricant. hole with Mopar® ATF +4,
Automatic Transmission fluid.
1) Transfer case not completely 1) With the transmission in
engaged in 4L position. NEUTRAL, or the clutch
depressed in the case of a manual
transmission and the vehicle
moving under 3­4 km/h (2­3 mph),

4636

Lubricant leaking from output
shaft seal or vent.
Abnormal tire wear.
REMOVAL
REMOVAL
Fig. 2: Skid Plate, Crossmember & Frame Rails
1 ­ SKID PLATE
2 ­ TRANSMISSION CROSSMEMBER
3 ­ FRAME RAILS
1. Shift transfer case into NEUTRAL.
2. Raise vehicle.
3. Remove skid plate (1) .
shift the transfer case to
NEUTRAL and then shift into the
4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair
linkage as necessary.
4) Range fork damaged, inserts 4) Disassemble unit and repair as
worn, or fork is binding on the necessary.
shift rail.
5) Low range gear worn or 5) Disassemble unit and repair as
damaged. necessary.
1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Vent closed or restricted. 2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or 3) Replace seal as necessary.
installed incorrectly. Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
1) Extended operation on hard, 1) Operate vehicle in the 2H
dry surfaces in the 4H position. position on hard, dry surfaces.
4637
 Fig. 3: Transfer Case Position Sensor & Connector

1 ­ TRANSFER CASE POSITION SENSOR CONNECTOR

2 ­ TRANSFER CASE POSITION SENSOR
3 ­ TRANSFER CASE
4 ­ OUTPUT SPEED SENSOR CONNECTOR

4. Drain transfer case lubricant.

5. Mark front and rear propeller shaft yokes for alignment reference.
6. Remove the front/rear propeller shafts at transfer case. Refer to Differential and Driveline/Propeller
Shaft/SHAFT , Drive ­ Removal
7. Disconnect transfer case position sensor connector (1) from the position sensor (2).

Fig. 4: Shift Cable Components

1 ­ TRANSFER CASE
2 ­ TRANSFER CASE SHIFT CABLE
3 ­ TRANSMISSION SHIFT CABLE
4 ­ AUTOMATIC TRANSMISSION
5 ­ TRANSFER CASE SHIFT CABLE BRACKET

8. Disconnect transfer case shift cable (2) at the range lever.

9. Disconnect the transfer case shift cable (2) from the shift cable bracket (5).

4638
 Fig. 5: Transfer Case

1 ­ AUTOMATIC TRANSMISSION
2 ­ TRANSFER CASE
3 ­ VENT HOSE
4 ­ FILL TUBE

10. Disconnect transfer case vent hose (3) .

11. Support transfer case (2) with transmission jack.
12. Secure transfer case to jack with chains.
13. Remove nuts attaching transfer case to transmission (1).
14. Pull transfer case and jack rearward to disengage transfer case.
15. Remove transfer case from under vehicle.

DISASSEMBL Y
DISASSEMBL Y

Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubricant remaining
in case.

COMPANION FLANGE AND RANGE LEVER

Fig. 6: Transfer Case Position Sensor

4639
1 ­ TRANSFER CASE POSITION SENSOR
2 ­ TRANSFER CASE

1. Remove transfer case position sensor (1) .

Fig. 7: Holding Companion Flange

1 ­ HOLDER C­3281
2 ­ BOLTS
3 ­ COMPANION FLANGE

2. Install two bolts (2) partially into the propeller shaft companion flange (3), 180° from each other.
3. Install the rectangular end of the Flange Holder C­3281 (1) over the bolts to hold the companion flange
stationary and remove the nut holding the companion flange to the output shaft.

Fig. 8: Removing Companion Flange

1 ­ TRANSFER CASE
2 ­ COMPANION FLANGE
3 ­ REMOVER C­452

4. Use Remover C­452 (3) to remove the companion flange (2).

4640
 Fig. 9: Range Lever & Bolt

1 ­ RANGE LEVER
2 ­ RANGE LEVER BOLT
3 ­ TRANSFER CASE

5. Remove seal washer from front output shaft. Discard washer as it should not be reused.
6. Remove the bolt (2) that attaches the range lever (1) to sector shaft. Then move sector to neutral position
and remove range lever from shaft.

NOTE: Be sure to note the orientation of the range lever (lever up or down) so
that it may be re­installed in the same direction.

REAR EXTENSION

Fig. 10: Rear Extension Bolts

1 ­ EXTENSION HOUSING
2 ­ TRANSFER CASE

1. Remove rear extension (1) bolts.

4641
 Fig. 11: Rear Extension Housing

1 ­ EXTENSION HOUSING
2 ­ TRANSFER CASE
3 ­ PRY SLOT

2. Remove rear extension housing (1) . Tap extension once or twice with a plastic mallet to break sealer
bead and loosen it.

Fig. 12: Output Shaft Bearing Retaining Ring

1 ­ REAR OUTPUT SHAFT

2 ­ OUTPUT SHAFT BEARING
3 ­ RETAINING RING
4 ­ TRANSFER CASE

3. Remove output bearing (2) retaining ring (3) with heavy duty snap­ring pliers.
OIL PUMP AND REAR CASE

4642
Fig. 13: Case Bolts

1 ­ REAR CASE
2 ­ FRONT CASE
3 ­ BOLT

1. Remove rear case(1)­to­front case (2) bolts (3) .

Fig. 14: Loosening Case Halves

1 ­ REAR CASE
2 ­ FRONT CASE
3 ­ PRY SLOTS

2. Loosen rear case (1) with pry tool to break sealer bead. Insert tool in slot (3) at each end of case.

4643
 Fig. 15: Removing Rear Case

1 ­ REAR CASE
2 ­ FRONT CASE

3. Unseat rear case (1) from alignment dowels.

4. Remove rear case and oil pump assembly from front case.

CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half.
The oil pump cover is aligned to the rear output shaft bearing inner race
and will become mis­aligned if the bolts are loosened. If the transfer case
failure has generated any debris which may have become trapped in the
oil pump, the rear case and oil pump assembly MUST be replaced.

FRONT OUTPUT SHAFT AND DRIVE CHAIN

Fig. 16: Shift Rail, Cup & Spring

1 ­ SHIFT RAIL
2 ­ SPRING
3 ­ CUP

1. Remove shift rail (1) cup (3) and spring (2) .

4644
 Fig. 17: Front Sprocket & Retaining Ring

1 ­ FRONT SPROCKET
2 ­ RETAINING RING
3 ­ FRONT OUTPUT SHAFT

2. Remove front sprocket (1) retaining ring (2) .

Fig. 18: Front Drive Sprocket & Drive Chain

1 ­ FRONT DRIVE SPROCKET

2 ­ DRIVE CHAIN
3 ­ MAINSHAFT

3. Pull mainshaft (3) , front sprocket (1) and chain outward about 25.4 mm (1­inch) simultaneously.
4. Remove chain from mainshaft drive sprocket and remove front sprocket and chain as assembly.
SHIFT FORKS AND MAINSHAFT

4645
Fig. 19: Detent Plug, Spring & Plunger

1 ­ FRONT CASE
2 ­ DETENT PLUG
3 ­ DETENT SPRING
4 ­ DETENT PLUNGER

1. Loosen detent plug (2) .

2. Remove detent plug (2), spring (3), and plunger (4). Note that the plug has an O­ring seal. Remove and
discard this seal.

Fig. 20: Front Output Shaft

1 ­ FRONT CASE
2 ­ FRONT OUTPUT SHAFT

3. Remove front output shaft (2) from bearing in the front case (1) .

4646
 Fig. 21: Mainshaft

1 ­ FRONT CASE
2 ­ MAINSHAFT

4. Pull mainshaft assembly (2) out of input gear, mode sleeve, and front case (1) .

Fig. 22: Mode Fork, Sleeve & Shift Rail

1 ­ MODE FORK
2 ­ SHIFT RAIL
3 ­ MODE SLEEVE

5. Remove mode fork (1), mode sleeve (3), and shift rail (2) as assembly. Note which way the sleeve fits in
the fork (long side of sleeve goes to front).

4647
 Fig. 23: Range Fork & Hub

1 ­ RANGE HUB
2 ­ RANGE FORK

6. Remove range fork retaining ring.

7. Remove range fork (2) and hub (1) as an assembly. Note fork position for installation reference.

Fig. 24: Shift Sector Support

1 ­ SECTOR SUPPORT
2 ­ FRONT CASE
3 ­ SECTOR SHAFT

8. Remove the shift sector support (1) .

4648
 Fig. 25: Shift Sector

1 ­ SHIFT SECTOR

9. Remove shift sector (1) .

MAINSHAFT

Fig. 26: Drive Sprocket Retaining Ring

1 ­ OUTPUT SHAFT
2 ­ RETAINING RING
3 ­ DRIVE SPROCKET

1. Remove the drive sprocket retaining ring (2) from the output shaft (1).

4649
 Fig. 27: Drive Sprocket Thrust Washer

1 ­ OUTPUT SHAFT
2 ­ THRUST WASHER
3 ­ DRIVE SPROCKET

2. Remove the drive sprocket (3) thrust washer (2) from the output shaft (1).

Fig. 28: Drive Sprocket

1 ­ OUTPUT SHAFT
2 ­ DRIVE SPROCKET

3. Remove drive sprocket (2) from the output shaft (1).

4650
 Fig. 29: Clutch Gear

1 ­ OUTPUT SHAFT
2 ­ CLUTCH GEAR
3 ­ MODE HUB

4. Remove the clutch gear (2) from the output shaft (1).

Fig. 30: Sprocket Hub

1 ­ OUTPUT SHAFT
2 ­ SPROCKET HUB

4651
 Fig. 31: Mode Hub & Retaining Ring

1 ­ OUTPUT SHAFT
2 ­ RETAINING RING
3 ­ MODE HUB

Remove the sprocket hub (2) from the output shaft (1).

5. Remove the mode hub (3) retaining ring (2) from the output shaft (1).

Fig. 32: Mode Hub

1 ­ OUTPUT SHAFT
2 ­ MODE HUB

6. Remove the mode hub (2) from the output shaft (1).

INPUT AND PLANETARY GEAR

4652
Fig. 33: Input Gear & Retaining Ring

1 ­ INPUT GEAR
2 ­ RETAINING RING

1. Remove input gear seal with suitable screw and slide hammer.
2. Remove input gear (1) retaining ring (2) with heavy duty snap­ring pliers.

Fig. 34: Input Planetary Assembly

1 ­ FRONT CASE
2 ­ INPUT PLANETARY ASSEMBLY

3. Place front case in horizontal position. Then remove input gear and low range gear as an assembly (2) .
Tap gear out of bearing with plastic mallet, if necessary.

INPUT AND PLANETARY GEAR

4653
Fig. 35: Input Gear Snap­Ring

1 ­ INPUT GEAR SNAP­RING

1. Remove snap­ring (1) that retains input gear in low range gear.

Fig. 36: Input Gear Retainer

1 ­ INPUT GEAR
2 ­ LOW RANGE GEAR
3 ­ RETAINER

2. Remove retainer (3) .

4654
 Fig. 37: Front Tabbed Thrust Washer

1 ­ FRONT TABBED THRUST WASHER

3. Remove front tabbed thrust washer (1) .

Fig. 38: Input Gear

1 ­ INPUT GEAR
2 ­ LOW RANGE GEAR

4. Remove input gear (1) .

4655
 Fig. 39: Rear Tabbed Thrust Washer

1 ­ LOW RANGE GEAR

2 ­ REAR TABBED THRUST WASHER

5. Remove rear tabbed thrust washer (2) from low range gear (1) .

CLEANING
CLEANING

Clean the transfer case parts with a standard parts cleaning solvent. Remove all traces of sealer from the cases
and retainers with a scraper and 3M™ all purpose cleaner. Use compressed air to remove solvent residue from
oil feed passages in the case halves, retainers, gears, and shafts.

INSPECTION
INSPECTION
MAINSHAFT/SPROCKET/HUB

Inspect the splines on the hub and shaft and the teeth on the sprocket. Minor nicks and scratches can be
smoothed with an oilstone, however, replace any part that is damaged.

Check the contact surfaces in the sprocket bore and on the mainshaft. Minor nicks and scratches can be
smoothed with 320­400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe.

INPUT GEAR AND PLANETARY CARRIER

Fig. 40: Input Gear & Carrier Components

1 ­ PLANETARY CARRIER 4 ­ CARRIER LOCK RING

2 ­ REAR THRUST WASHER 5 ­ CARRIER LOCK RETAINING RING
3 ­ FRONT THRUST WASHER 6 ­ INPUT GEAR

Check the teeth on the input gear (6) . Minor nicks can be dressed off with an oilstone but replace the gear if
any teeth are broken, cracked, or chipped. The bearing surface on the gear can be smoothed with 300­400 grit
emery cloth if necessary.

4656
Examine the planetary carrier body (1) and pinion gears for wear or damage. The carrier will have to be
replaced as an assembly if the body, pinion pins, or pinion gears are damaged.

Check the carrier lock ring (4) and both thrust washers (2, 3) for wear or cracks. Replace them if necessary.
Also replace the carrier lock retaining ring (5) if bent, distorted, or broken.
SHIFT FORKS/HUBS/SLEEVES

Fig. 41: Shift Fork & Mode Fork Shift Rail

1 ­ RANGE FORK
2 ­ MODE FORK AND RAIL
3 ­ MODE SPRING

Check condition of the shift forks and mode fork shift rail (2) . Minor nicks on the shift rail can be smoothed
with 320­400 grit emery cloth.

Fig. 42: Shift Fork & Wear Pads

1 ­ RANGE FORK
2 ­ MODE FORK
3 ­ WEAR PADS (SERVICEABLE)
4 ­ WEAR PADS (SERVICEABLE)

Inspect the shift fork wear pads (3, 4) . The mode fork pads are serviceable and can be replaced if necessary.
The range fork pads are not serviceable. The fork must be replaced as an assembly if the pads are worn or
damaged.
4657
Check both of the sleeves for wear or damage, especially on the interior teeth. Replace the sleeves if wear or
damage is evident.

REAR RETAINER COMPONENTS

Inspect the retainer components. Replace the bearing if rough or noisy. Check the retainer for cracks or wear in
the bearing bore.

Inspect the retaining rings and washers. Replace any part if distorted, bent, or broken. Reuse is not
recommended.

Inspect rear extension bushing. Replace if worn or scored.

DRIVE CHAIN

Examine the drive chain and shaft bearings. replace the chain if stretched, distorted, or if any of the links bind.
Replace the bearings if rough, or noisy.
LOW RANGE ANNULUS GEAR

Fig. 43: Low Range Annulus Gear

1 ­ FRONT CASE
2 ­ LOW RANGE ANNULUS GEAR

Inspect annulus gear (2) condition carefully. The gear is only serviced as part of the front case. If the gear is
damaged, it will be necessary to replace the gear and front case as an assembly. Do not attempt to remove the
gear.
FRONT CASE AND REAR CASE

Inspect the cases for wear and damage.

Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces.
Also make sure the front case mounting studs are in good condition.

Check the front case mounting studs and vent tube. The tube can be secured with Loctite™ 271 or 680 if loose.
The stud threads can be cleaned up with a die if necessary. Also check condition of the fill/drain plug threads in
the rear case. The threads can be repaired with a thread chaser or tap if necessary. Or the threads can be repaired
with Helicoil™ stainless steel inserts if required.
OIL PUMP/OIL PICKUP

4658
Examine the oil pump pickup parts. Replace the pump if any part appears to be worn or damaged. Do not
disassemble the pump as individual parts are not available. The pump is only available as a complete assembly.
The pickup screen, hose, and tube are the only serviceable parts and are available separately.

ASSEMBLY
ASSEMBLY
BEARINGS AND SEALS

Fig. 44: Input Gear Bearing

1 ­ INPUT GEAR BEARING

2 ­ FRONT CASE

1. Remove the input shaft bearing (1) from the front case (2) with suitable snap­ring pliers.
2. Transfer the retaining ring to the new bearing if necessary and install the bearing into the front case.

Fig. 45: Front Output Shaft Bearing

1 ­ FRONT CASE
2 ­ INSTALLER 6436
3 ­ UNIVERSAL HANDLE C­4171

3. Using Installer 6436 (2) and Universal Handle C­4171 (3) , remove front output shaft bearing.

4659
4. Start front output shaft bearing in case. Then seat bearing with Universal Handle C­4171 and Bearing
Installer 6953.
5. Install front output shaft bearing retaining ring.

Fig. 46: Input Gear Pilot Bearing

1 ­ DRIFT
2 ­ INPUT GEAR

6. Remove input gear pilot bearing by inserting a suitably sized drift (1) into the splined end of the input
gear (2) and driving the bearing out with the drift and a hammer.
7. Install new pilot bearing with Bearing Installer 8684.

Fig. 47: Output Shaft Rear Bearing

4660
 1 ­ REAR CASE
2 ­ SPECIAL TOOL L­4454­1 AND L­4454­3
3 ­ SPECIAL TOOL 8148

8. Remove the front output shaft rear bearing with the screw and jaws from Remover L­4454A (2) and Cup
8148 (3) .

Fig. 48: Output Shaft Inner Bearing

1 ­ HANDLE C­4171
2 ­ OUTPUT SHAFT INNER BEARING
3 ­ INSTALLER 5066

9. Install new bearing with Universal Handle C­4171 (1) and Bushing Installer 5066 (3) .

Fig. 49: Bearing Installation Depth

1 ­ BEARING (SEATED) AT LOWER EDGE OF

CHAMFER
2 ­ CHAMFER

4661
 10. The bearing bore is chamfered (1) at the top. Install the bearing so it is flush with the lower edge of this
chamfer.

Fig. 50: Rear Output Shaft Bearing

1 ­ REAR CASE
2 ­ REMOVER/INSTALLER 8684
3 ­ HANDLE C­4171

11. Remove the rear output shaft bearing from the rear case using Bearing Installer 8684 (2) and Universal
Handle C­4171 (3) .

Fig. 51: Rear Output Shaft Bearing

1 ­ REAR CASE
2 ­ REMOVER/INSTALLER 6953
3 ­ HANDLE C­4171

12. Install the rear output shaft bearing into the rear case (1) using Bearing Installer 6953 (2) and Universal
Handle C­4171 (3).

INPUT AND PLANETARY GEAR

4662
Fig. 52: Input/Low Range Gear Components

1 ­ SNAP­RING
2 ­ RETAINER PLATE
3 ­ INPUT GEAR
4 ­ LOW RANGE GEAR
5 ­ THRUST WASHERS

1. Lubricate gears (3, 4) and thrust washers (5) with recommended transmission fluid.
2. Install first thrust washer (5) in low range gear (3). Be sure washer tabs are properly aligned in gear
notches.
3. Install input gear (3) in low range gear (4). Be sure input gear is fully seated.
4. Install remaining thrust washer (5) in low range gear (4) and on top of input gear (3). Be sure washer tabs
are properly aligned in gear notches.
5. Install retainer (2) on input gear and install snap­ring (1).

Fig. 53: Input Planetary Assembly

1 ­ FRONT CASE
4663
 2 ­ INPUT PLANETARY ASSEMBLY

6. Align and install low range/input gear assembly (2) in front case (1) . Be sure low range gear pinions are
engaged in annulus gear and that input gear shaft is fully seated in front bearing.

Fig. 54: Input Gear & Retaining Ring

1 ­ INPUT GEAR
2 ­ RETAINING RING

7. Install snap­ring (2) to hold input/low range gear (1) into front bearing.
8. Install a new input gear seal using Installer 8841 and Universal Handle C­4171.

SHIFT FORKS AND MAINSHAFT

Fig. 55: Mode Hub

1 ­ OUTPUT SHAFT
2 ­ MODE HUB

1. Lubricate mainshaft splines with recommended transmission fluid.

2. Install the mode hub (1) onto the output shaft.

4664
 Fig. 56: Mode Hub Retaining Ring

1 ­ OUTPUT SHAFT
2 ­ RETAINING RING
3 ­ MODE HUB

3. Install the mode hub retaining ring (2) onto the output shaft (1).

Fig. 57: Sprocket Hub

1 ­ OUTPUT SHAFT
2 ­ SPROCKET HUB

4. Install the sprocket hub (2) onto the output shaft (1).

4665
 Fig. 58: Clutch Gear

1 ­ OUTPUT SHAFT
2 ­ CLUTCH GEAR
3 ­ MODE HUB

5. Install the clutch gear (2) onto the output shaft (1).

Fig. 59: Drive Sprocket

1 ­ OUTPUT SHAFT
2 ­ DRIVE SPROCKET

6. Install the drive sprocket (2) onto the output shaft (1).

4666
 Fig. 60: Drive Sprocket Thrust Washer

1 ­ OUTPUT SHAFT
2 ­ THRUST WASHER
3 ­ DRIVE SPROCKET

7. Install the drive sprocket (3) thrust washer (2) onto the output shaft (1).

Fig. 61: Drive Sprocket Retaining Ring

1 ­ OUTPUT SHAFT
2 ­ RETAINING RING
3 ­ DRIVE SPROCKET

8. Install the drive sprocket retaining ring (2) onto the output shaft (1).

4667
 Fig. 62: Shift Sector

1 ­ SHIFT SECTOR

9. Lubricate sector shaft with transmission fluid and install shift sector (1) in case. Position slot in sector so
it will be aligned with shift fork pin when shift forks are installed.

Fig. 63: Shift Sector Support

1 ­ SECTOR SUPPORT
2 ­ FRONT CASE
3 ­ SECTOR SHAFT

10. Install the shift sector support (1) . Tighten the sector support to 27­42 N.m (20­30 ft.lbs.).

4668
 Fig. 64: Range Fork & Hub Assembly

1 ­ RANGE HUB
2 ­ RANGE FORK

11. Assemble and install range fork (2) and hub (1) . Be sure hub is properly seated in low range gear and
engaged to the input gear.
12. Align and insert range fork pin in shift sector slot.
13. Install the range fork retaining ring.

Fig. 65: Mode Fork & Shift Rail

1 ­ MODE FORK
2 ­ SHIFT RAIL
3 ­ MODE SLEEVE

14. Install mode fork (1) and shift rail (2) onto the mode sleeve (3).
15. Install the mode fork, sleeve, and shift rail into the transfer case.

4669
 Fig. 66: Mainshaft

1 ­ FRONT CASE
2 ­ MAINSHAFT

16. Install mainshaft (2) into the transfer case (1) . Guide mainshaft through the mode and range sleeves and
into the input gear.

Fig. 67: O­Ring & Detent Plug

1 ­ O­RING
2 ­ DETENT PLUG

17. Install new o­ring on detent plug (2) .

4670
 Fig. 68: Detent Plug, Spring & Plunger

1 ­ FRONT CASE
2 ­ DETENT PLUG
3 ­ DETENT SPRING
4 ­ DETENT PLUNGER

18. Install detent plunger (4), spring (3), and plug (2) . Tighten the plug to 16­25 N.m (12­18 ft. lbs.).

FRONT OUTPUT SHAFT AND DRIVE CHAIN

Fig. 69: Front Output Shaft

1 ­ FRONT CASE
2 ­ FRONT OUTPUT SHAFT

1. Install the front output shaft (2) into the front output shaft bearing.

Fig. 70: Front Sprocket & Drive Chain

1 ­ FRONT DRIVE SPROCKET

2 ­ DRIVE CHAIN
3 ­ MAINSHAFT

4671
2. Insert front sprocket in drive chain.
3. Install drive chain (2) around mainshaft sprocket (1) . Then position front sprocket over front shaft.
4. Raise mainshaft about 2.54 cm (one inch) and seat front sprocket on front output shaft.

Fig. 71: Front Sprocket Retaining Ring

1 ­ FRONT SPROCKET
2 ­ RETAINING RING

5. If mainshaft and mode sleeve were unseated during chain installation, align and reseat mainshaft in input
gear and hub.
6. Install front sprocket (1) retaining ring (2) .

Fig. 72: Shift Rail Spring & Cup

1 ­ CUP
2 ­ SPRING

7. Install spring (2) and cup (1) on shift rail.

4672
 Fig. 73: Magnet & Case Pocket

1 ­ MAGNET
2 ­ CASE POCKET

8. Insert magnet (1) in front case pocket (2) .

OIL PUMP AND REAR CASE

Fig. 74: Front & Rear Cases

1 ­ REAR CASE
2 ­ FRONT CASE

CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half. The
oil pump cover is aligned to the rear output shaft inner bearing race and will
become mis­aligned if the bolts are loosened. If the transfer case failure has
generated any debris which may have become trapped in the oil pump. the rear
case and oil pump assembly MUST be replaced.

1. Apply bead of Mopar® Gasket Maker, or equivalent, to mating surface of front case. Keep sealer bead
width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess will be displaced into
case interior.
2. Align oil pump with mainshaft and align shift rail with bore in rear case. Then install rear case (1) and oil
pump assembly.

4673
 Fig. 75: Case Bolts

1 ­ REAR CASE
2 ­ FRONT CASE
3 ­ BOLT

3. Install 4­5 rear case(1)­to front case (2) bolts to hold rear case in position. Tighten bolts snug but not to
specified torque at this time.

CAUTION: Verify that shift rail, and case alignment dowels are seated before
installing any bolts. Case could be cracked if shaft rail or dowels are
misaligned.

Fig. 76: Output Shaft Bearing Retaining Ring

1 ­ REAR OUTPUT SHAFT

2 ­ OUTPUT SHAFT BEARING
3 ­ RETAINING RING
4 ­ TRANSFER CASE

4. Apply Loctite™ 242 to remainder of rear case­to­front case bolt threads and install bolts. Tighten bolts to
20­27 N.m (15­24 ft. lbs.),
5. Install rear output bearing (2) snap­ring (3) to output shaft.

REAR EXTENSION

4674
Fig. 77: Rear Extension Bolts

1 ­ EXTENSION HOUSING
2 ­ TRANSFER CASE

1. Install new seal in rear extension housing seal with Installer D­163 and Universal Handle C­4171.
2. Apply bead of Mopar® Gasket Maker, or equivalent, to mating surface of rear extension housing. Keep
sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess could be
displaced into output bearing.
3. Align and install rear extension housing (1) on retainer.
4. Apply Mopar® Silicone Sealer to threads of rear extension housing bolts. Then install and tighten bolts
to 16­24 N.m (12­18 ft. lbs.) torque.

COMPANION FLANGE AND RANGE LEVER

Fig. 78: Range Lever & Bolt

1 ­ RANGE LEVER
2 ­ RANGE LEVER BOLT
3 ­ TRANSFER CASE

1. Install range lever (1) and bolt (2) on sector shaft. Tighten bolt to 27­34 N.m (20­25 ft. lbs.) torque.

4675
 Fig. 79: Transfer Case Position Sensor

1 ­ TRANSFER CASE POSITION SENSOR

2 ­ TRANSFER CASE

2. Inspect the o­ring on the transfer case position sensor. Replace the o­ring if necessary.
3. Install the transfer case position sensor (1) in the front case (2) . Tighten sensor to 20­34 N.m (15­25 ft.
lbs.) torque.

Fig. 80: Seal Washer

1 ­ SEAL WASHER

4. Install new seal washer (1) on front output shaft.

5. Lubricate companion flange hub with transmission fluid and install flange onto the front output shaft.
6. Install new flange nut onto front output shaft.
7. Tighten flange nut to 122­176 N.m (90­130 ft. lbs.) torque.

INSTALLATION
INSTALLATION

4676
Fig. 81: Transmission & Transfer Case

1 ­ AUTOMATIC TRANSMISSION
2 ­ TRANSFER CASE
3 ­ VENT HOSE
4 ­ FILL TUBE

1. Mount transfer case on a transmission jack.

2. Secure transfer case to jack with chains.
3. Position transfer case under vehicle.
4. Align transfer case and transmission shafts and install transfer case on transmission.
5. Install and tighten transfer case attaching nuts to 35 N.m (26 ft. lbs.) torque.
6. Connect vent hose (3) .

Fig. 82: Transfer Case Position Sensor, Output Speed Sensor & Connectors

1 ­ TRANSFER CASE POSITION SENSOR CONNECTOR

2 ­ TRANSFER CASE POSITION SENSOR
3 ­ TRANSFER CASE
4 ­ OUTPUT SPEED SENSOR CONNECTOR

7. Connect transfer case position sensor connector (1) to sensor (2).

8. Align and connect propeller shafts. Refer to Differential and Driveline/Propeller Shaft/SHAFT, Drive
­ Installation .
4677
 Fig. 83: Shift Cables

1 ­ TRANSFER CASE
2 ­ TRANSFER CASE SHIFT CABLE
3 ­ TRANSMISSION SHIFT CABLE
4 ­ AUTOMATIC TRANSMISSION
5 ­ TRANSFER CASE SHIFT CABLE BRACKET

9. Connect shift cable (2) to transfer case range (1) lever.

Fig. 84: Skid Plate, Crossmember & Frame Rails

1 ­ SKID PLATE
2 ­ TRANSMISSION CROSSMEMBER
3 ­ FRAME RAILS

10. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
11. Install skid plate (1) . Refer to Frame and Bumpers/Under Body Protection/PLA TE, Skid ­
Installation
12. Remove transmission jack and support stand.
13. Lower vehicle and verify transfer case shift operation.

4678
SPECIFICA TIONS
TORQUE

TORQUE
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Extension Housing 16-24 12-18 -
Bolt, Case Half 20-27 15-24 -
Screw, Oil Pump 12-16 8-12 -
Nut, Front Companion 122-176 90-130
-
Flange
Nut, Range Lever 27-34 20-25 -
Sector Support 27-42 20-30 -
Nuts, Mounting 30-41 20-30 -
Position Sensor 20-34 16-25 -

SPECIAL TOOLS
SPECIAL TOOLS

Fig. 85: ADAPTER, BEARING/GEAR ­ C­293­3

Fig. 86: PULLER, COMPANION FLANGE ­ C­452

Fig. 87: HOLDER, FLANGE ­ C­3281

4679
Fig. 88: DRIVER HANDLE, UNIVERSAL ­ C­4171

Fig. 89: SLIDE HAMMER, UNIVERSAL ­ C­637

Fig. 90: PULLER, PULLEY ­ C­4333A

Fig. 91: INSTALLER, SEAL ­ C­4210

4680
Fig. 92: INSTALLER, SEAL ­ D­163

Fig. 93: REMOVER, BEARING CUP ­ L­4454

Fig. 94: INSTALLER, BUSHING­ 5066

Fig. 95: INSTALLER, BEARING ­ 6436

Fig. 96: INSTALLER, SEAL ­ 6888

Fig. 97: INSTALLER, SEAL ­ 6952A

4681
Fig. 98: REMOVER/INSTALLER, BEARING ­ 6953

Fig. 99: REMOVER, BUSHING ­ 6957

Fig. 100: INSTALLER, SEAL ­ 7884

Fig. 101: INSTALLER, SEAL ­ 7888

Fig. 102: CUP ­ 8148

4682
Fig. 103: INSTALLER, BUSHING ­ 8157

Fig. 104: INSTALLER, BEARING ­ 8684

CABLE, SHIFT
REMOVAL
REMOVAL

Fig. 105: Shift Cable At Transfer Case

NOTE: Transfer Case may not engage or disengage Four Wheel Drive Mode if the
transfer case shift cable end bushings are damaged.

4683
 1. Shift transfer case into N.
2. Raise vehicle.
3. Remove clip securing the transfer case shift cable (2) to the shift cable support bracket.
4. Disengage any additional shift cable routing clips, if necessary.
5. Disengage the shift cable from the transfer case manual lever.
6. If necessary remove end bushing from shift cable end.

Fig. 106: Shift Cable At Shift Lever

7. Lower the vehicle.

8. Remove the floor console as necessary to access the shifter mechanism. Refer to
Body/Interior/CONSOLE, Center ­ Removal
9. Disengage the transfer case shift cable from the shift lever pin and body.
10. Disengage the shift cable grommet from the floor and remove the shift cable from the vehicle.
11. If necessary remove end bushing from shift cable end.

INSTALLATION
INSTALLATION

4684
Fig. 107: Shift Cable At Shift Lever

NOTE: Transfer Case may not engage or disengage Four Wheel Drive Mode if the
transfer case shift cable end bushings are damaged.

1. If necessary install new end bushings on the shift cable ends.

2. Route the shift cable through the opening in the floor pan.
3. Connect the transfer case shift cable to the shift lever body and pin.
4. Install any floor console components previously removed. Refer to Body/Interior/CONSOLE, Center ­
Installation
5. Verify that the floor shifter is in the N position.

Fig. 108: Shift Cable At Transfer Case

4685
 6. Raise vehicle.
7. Route the shift cable through the opening in the shift cable support bracket.
8. Install the cable and a new spring clip into the slot in the support bracket.
9. Install any additional routing clips on the shift cable.
10. Verify that the transfer case is in the N position.
11. Attach the shift cable to the transfer case manual lever.
12. Lower vehicle and check for proper transfer case shifter operation.

FLUID
STANDARD PROCEDURE
FLUID DRAIN AND FILL

Fig. 109: Fill/Drain Plugs & I.D. Tag

1 ­ I.D. TAG
2 ­ FILL PLUG
3 ­ DRAIN PLUG

The fill (2) and drain (3) plugs are both in the rear case. Correct fill level is to the bottom edge of the fill plug
hole. Be sure the vehicle is level to ensure an accurate fluid level check.

HANDLE
REMOVAL
REMOVAL

NOTE: Manual transmission shifter assembly shown. Automatic transmission shifter

assembly typical.

NOTE: Most handles can be remove by hand. The motion should mimic that of a slide
hammer . Constant force doesn't aid in the removal of the handle.

4686
Fig. 110: Shift lever Components

1. Slide the shift lever (2) back towards the seat and pull in an upward motion with a "quick" snap to
remove the handle (1).

Fig. 111: Removing/Installing Shift Lever Handle

2. If removal of the handle by hand is not possible wrap a shop towel or equivalent (4) around the base of
the handle (3) and using puller C­4333A­1 or equivalent (2) and slide hammer (1), remove the handle (3)
from the shift lever.

INSTALLATION
INSTALLATION

4687
Fig. 112: Shift lever Components

1. Install the shift handle (1) onto the shift lever (2) and firmly push the shift handle (1) down, a audible
click should be heard when the shift handle (1) is seated in position.

LEVER, TRANSFER CASE

REMOVAL
REMOVAL

Fig. 113: Shift Cable At Shift Lever

1. Shift transfer case into 4L.

2. Remove the floor console as necessary to access the shifter mechanism. Refer to
Body/Interior/CONSOLE, Center ­ Removal
3. Disengage the transfer case shift cable from the shift lever pin and body.

4688
 Fig. 114: Shift Lever Assembly

4. Remove the nuts attaching lever assembly (1) to floorpan and remove assembly (2).
5. Remove the shifter mechanism from the vehicle.

INSTALLATION
INSTALLATION

Fig. 115: Shift Lever Assembly

1. Position the shift mechanism over the shifter retaining studs on the floor pan.
2. Install the nuts to hold the shifter mechanism to the floor pan. Tighten the nuts to 11.9 N.m (105 in.lbs.).

4689
 Fig. 116: Shift Cable At Shift Lever

3. Verify that the floor shifter is in the 4L position.

4. Connect the transfer case shift cable to the shift lever body and pin.
5. Install any floor console components previously removed. Refer to Body/Interior/CONSOLE, Center ­
Installation
6. Check for proper transfer case shifter operation.

SEAL, OUTPUT SHAFT, EXTENSION HOUSING

REMOVAL
REMOVAL

1. Raise and support vehicle.

2. Remove rear propeller shaft. Refer to Differ ential and Driveline/Propeller Shaft/SHAFT, Drive ­
Removal
3. Using a suitable pry tool or slide­hammer mounted screw, remove the extension housing seal.

INSTALLATION
INSTALLATION

Fig. 117: Installing Extension Housing Seal

4690
1 ­ SPECIAL TOOL C­4171
2 ­ SPECIAL TOOL D­163

1. Clean fluid residue from sealing surface and inspect for defects.
2. Using Seal Installer D­163 (2) and Universal Handle C­4171 (1), install seal in extension housing .
3. Install propeller shaft. Refer to Differ ential and Driveline/Propeller Shaft/SHAFT, Drive ­
Installation
4. Verify proper transfer case fluid level.
5. Lower vehicle.

SEAL, OUTPUT SHAFT, FRONT

REMOVAL
REMOVAL

Fig. 118: Front Output Shaft Seal

1 ­ OUTPUT SHAFT SEAL

2 ­ PRYBAR

1. Raise vehicle.
2. Remove front propeller shaft. Refer to Differ ential and Driveline/Propeller Shaft/SHAFT, Drive ­
Removal
3. Remove front output shaft companion flange.
4. Remove seal (1) from front case with pry tool (2) .

INSTALLATION
INSTALLATION

4691
Fig. 119: Installing Front Output Seal

1 ­ INSTALLER 6952A
2 ­ TRANSFER CASE

1. Install new front output seal in front case (2) with Seal Installer 6952A (1) as follows:
a. Place new seal on tool. Garter spring on seal goes toward interior of case.
b. Start seal in bore with light taps from hammer. Once seal is started, continue tapping seal into bore
until installer tool seats against case.
2. Install the front output shaft companion flange. Tighten the companion flange nut to 149 N.m (110
ft.lbs.).
3. Install the front propeller shaft. Refer to Differ ential and Driveline/Propeller Shaft/SHAFT, Drive ­
Installation

SENSOR, POSITION
DESCRIPTION
DESCRIPTION

Fig. 120: Transfer Case Position Sensor

1 ­ TRANSFER CASE POSITION SENSOR

2 ­ TRANSFER CASE

4692
The transfer case position sensor (2) is an electronic device whose output can be interpreted to indicate the
transfer case's current operating mode. The sensor consists of a five position, resistive multiplexed circuit which
returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating
mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides
against the sector plate roostercomb. The PCM supplies 5VDC (+/­ 0.5V) to the sensor and monitors the return
voltage to determine the sector plate, and therefore the transfer case, position.

OPERA TION
OPERATION

Fig. 121: Position Sensor Linear Movement

1 ­ POSITION 1 ­ 10mm ±0.5mm

2 ­ POSITION 2 ­ 12mm ±0.5mm
3 ­ POSITION 3 ­ 14mm ±0.5mm
4 ­ POSITION 4 ­ 16mm ±0.5mm
5 ­ POSITION 5 ­ 18mm ±0.5mm
6 ­ POSITION 6 ­ 20mm±0.5mm ­ FULL EXTENSION

During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position
sensor return voltage to determine the operating mode of the transfer case. Refer to the Operating Mode
Versus Resistance table for the correct resistance for each position.

Operating Mode Versus Resistance

SENSOR POSITION OPERA TING MODE SENSOR RESISTANCE (ohms)
1 2WD 1124-1243
2 4WD PART TIME 650-719
3 4WD FULL TIME 389-431
4 NEUTRAL 199-221
5 4WD LOW 57-64

REMOVAL
REMOVAL

4693
Fig. 122: Transfer Case Position Sensor

1 ­ TRANSFER CASE POSITION SENSOR

2 ­ TRANSFER CASE

1. Raise and support the vehicle.

2. Disengage the transfer case position sensor connector from the position sensor (2) .
3. Remove the position sensor from the transfer case.

INSTALLATION
INSTALLATION

Fig. 123: Transfer Case Position Sensor

1 ­ TRANSFER CASE POSITION SENSOR

2 ­ TRANSFER CASE

1. Inspect the o­ring seal on the transfer case position sensor (1) . Replace the o­ring if necessary.
2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 N.m (20 ft.lbs.).
3. Engage the transfer case position sensor connector to the position sensor.
4. Lower vehicle.
5. Verify proper sensor operation.

4694
4695